IP Library Granted Patent US 12,233,628
Granted Patent B2
US 12,233,628 · App. 17/273,372 · Granted Feb 25, 2025

Multilayer film

Inventors: Jingbo Wang (Linz, AT); Markus Gahleitner (Linz, AT); Klaus Bernreitner (Linz, AT); Pauli Leskinen (Porvoo, FI); Peter Niedersuss (Linz, AT)
Assignee: BOREALIS AG
B32B27/08B32B27/325B32B27/327C08F210/06C08L23/08C08L23/142B32B2250/03B32B2250/246B32B2270/00B32B2307/31B32B2553/00
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Quick Facts
Patent No.
US 12,233,628
App. No.
17/273,372
Granted
Feb 25, 2025
Kind
B2
Abstract

Multilayer film of at least three layers, one core layer and at least one sealing layer wherein the sealing layer comprises a linear low density polyethylene having a density in the range of 0.915 to 0.925 g/cm 3 , and the core layer comprises a propylene 1-hexene copolymer, said copolymer has an 1-hexene content in the range of 2.0 to 5.0 wt.-% and a xylene soluble fraction in the range of 0.3 to 15.0 wt.-%.

Claims (98)

1. The multilayer film comprising at least three layers, one 1 st sealing layer (SL1), one core layer (CL) and one outer layer (OL), the stacking order of the at least three layers is (SL1)/(CL)/(OL),

wherein:

(a) the 1 st sealing layer (SL1) comprises at least 90 wt. %, based on the total weight of the 1 st sealing layer (SL1), of a 1 st base polymer composition (BC1), said 1 st base polymer composition (BC1) comprises at least 70 wt. %, based on the total weight of the 1 st base polymer composition (BC1), of a 1 st linear low density polyethylene (LLDPE1), said 1 st linear low density polyethylene (LLDPE1) has a density in the range of 0.890 to 0.925 g/cm 3 measured according to ISO 1183-187;

(b) the core layer (CL) comprises at least 90 wt. %, based on the total weight of the core layer (CL), of a 2 nd base polymer composition (BC2), wherein the core layer (CL) contains the 2 nd base polymer composition (BC2) as the only polymer; and

(c) the outer layer (OL) comprises at least 90 wt. %, based on the total weight of the outer layer (OL), of a 3 rd base polymer composition (BC3), said 3 rd base polymer composition (BC3) comprises at least 90 wt. %, based on the total weight of the 3 rd base polymer composition (BC3), of a polyolefin;

wherein said 2 nd base polymer composition (BC2)

is a mixture of the propylene 1-hexene copolymer (PHC) and a plastomer (PL), said plastomer being an elastomeric copolymer of ethylene and at least one C 4 to C 10 α-olefin;

wherein said propylene 1-hexene copolymer (PHC) of the 2 nd base polymer composition (BC2) has

(i) an 1-hexene content in the range of 2.0 to 5.0 wt. % based on the total weight of the propylene 1-hexene copolymer (PHC); and

(ii) a xylene soluble fraction (XCS) determined at 25° C. according to ISO 16152 in the range of 0.3 to 15.0 wt. % based on the total weight of the xylene soluble fraction (XCS) of the 1-hexene copolymer (PHC), the xylene soluble fraction (XCS) having a 1-hexene content in the range of 2.5 to 7.0 wt. %, based on the total weight of the xylene soluble fraction (XCS) of the propylene 1-hexene copolymer (PHC);

wherein the propylene 1-hexene copolymer (PHC) comprises:

(a) a 1 st propylene 1-hexene copolymer (PHC-1) having an 1-hexene content in the range of 0.7 to 2.5 wt. % based on the total weight of the 1st propylene 1-hexene copolymer (PHC-1); and

(b) a 2 nd propylene 1-hexene copolymer (PHC-2) having an 1-hexene content in the range of 2.8 to 5.5 wt. %, based on the total weight of the 2 nd propylene 1-hexene copolymer (PHC-2).

2. The multilayer film according to claim 1 , wherein:

(a) the total amount of the 1 st propylene 1-hexene copolymer (PHC-1) and the 2 nd propylene 1-hexene copolymer (PHC-2) together in the propylene 1-hexene copolymer (PHC) is at least 95 wt. % based on the total weight of the propylene 1-hexene copolymer (PHC); or

(b) the propylene 1-hexene copolymer (PHC) consists of the propylene 1-hexene copolymers PHC-1 and PHC-2.

3. The multilayer film according to claim 1 , wherein the weight ratio [(PHC-1)/(PHC-2)] between the 1 st propylene 1-hexene copolymer (PHC-1) and the 2 nd propylene 1-hexene copolymer (PHC-2) is in the range of 30/70 to 50/50.

4. The multilayer film according to claim 1 , wherein the propylene 1-hexene copolymer (PHC)

(a) fulfills the inequation (I):

5.00

C

6

(

PHC

)

C

6

(

PHC

-

1

)

*

[

PHC

-

1

]

{

PHC

]

7.50

(

I

)

wherein

C6 (PHC-1) is the 1-hexene content of the 1 st propylene 1-hexene copolymer (PHC-1) based on the total weight of the 1 st propylene 1-hexene copolymer (PHC-1) [in wt. %];

C6 (PHC) is the 1-hexene content of the propylene 1-hexene copolymer (PHC) based on the total weight of the propylene 1-hexene copolymer (PHC) [in wt. %];

[PHC-1]/[PHC] is the weight ratio between the 1 st propylene 1-hexene copolymer (PHC-1) and the propylene 1-hexene copolymer (PHC) [in g/g].

5. The multilayer film according to claim 1 , wherein the propylene 1-hexene copolymer (PHC) has:

(a) a xylene soluble fraction (XCS) determined at 25° C. according to ISO 16152 in the range of 0.3 to 9.5 wt. % based on the total weight of the xylene soluble fraction (XCS) of the 1-hexene copolymer (PHC) or

(b) an 1-hexene content in the range of 2.5 to 4.0 wt. %, based on the total weight of the propylene 1-hexene copolymer (PHC).

6. The multilayer film according to claim 1 , wherein the propylene 1-hexene copolymer (PHC) has:

(a) a molecular weight distribution (MWD) in the range of 3.0 to 4.3; and

(b) 2,1 erythro regio defects in the range of 0.40 to 0.55 mol.-% determined by 13C NMR spectroscopy.

7. The multilayer film according to claim 1 , wherein the propylene 1-hexene copolymer (PHC) has:

(a) a melting temperature in the range of 133 to 139° C. measured according to ISO 11357; and

(b) a melt flow rate MFR2 (230° C./2.16 kg) measured according to ISO 1133 in the range of 0.5 to 8.0 g/10 min.

8. The multilayer film according to claim 1 , wherein:

(a) the core layer (CL) comprises at least 90 wt. %, based on the total weight of the core layer (CL), of the 2 nd base polymer composition (BC2) and the remaining part up to 100 wt. %, based on the total weight of the core layer (CL), are additives (AD) selected from the group consisting of antioxidants, light stabilizers, acid scavengers, processing aids, anti-blocking aids, nucleating agents, slip agents and mixtures thereof; and

(b) the 1 st sealing layer (SL1) comprises at least 90 wt. %, based on the total weight of the 1 st sealing layer (SL1), of the 1 st base polymer composition (BC1) and the remaining part up to 100 wt. %, based on the total weight of the 1 st sealing layer (SL1), are additives (AD) selected from the group consisting of antioxidants, light stabilizers, acid scavengers, processing aids, anti-blocking aids, nucleating agents, slip agents and mixtures thereof; and

(c) the outer layer (OL) comprises at least 90 wt. %, based on the total weight of the outer layer (OL), of the 3 rd base polymer composition (BC3) and the remaining part up to 100 wt. %, based on the total weight of the outer layer (OL), are additives (AD) selected from the group consisting of antioxidants, light stabilizers, acid scavengers, processing aids, anti-blocking aids, nucleating agents, slip agents and mixtures thereof.

9. The multilayer film according to claim 1 , wherein the 2 nd base polymer composition (BC2) comprises:

(a) 75 to 95 wt. %, based on the total weight of the 2 nd base polymer composition (BC2), of the propylene 1-hexene copolymer (PHC), and

(b) 5 to 25 wt. %, based on the total weight of the 2 nd base polymer composition (BC2), of the plastomer (PL).

10. The multilayer film according to claim 1 , wherein the plastomer (PL) has a glass transition temperature in the range of −60 to −35° C.

11. The multilayer film according to claim 1 , wherein the plastomer (PL) has:

(a) a density in the range of 0.860 to 0.930 g/cm 3 measured according to ISO 1183-187; and

(b) an ethylene content in the range of 65.0 to 95.0 wt. %.

12. The multilayer film according to claim 1 , wherein the plastomer (PL) has a melting temperature below 100° C.

13. The multilayer film according to claim 1 , wherein the outer layer (OL) is:

(a) a heat shield layer (HSL) comprising at least 90 wt. %, based on the total weight of the heat shield layer (HSL), of a 3 rd base polymer composition (BC3B) and the remaining part up to 100 wt. %, based on the total weight of the heat shield layer (HSL), are additives (AD) said 3 rd base polymer composition (BC3B) comprises at least 90 wt. %, based on the total weight of the 3 rd base polymer composition (BC3B), of a polypropylene having a melting temperature of at least 150° C. measured according to ISO 11357, or

(b) a 2 nd sealing layer (SL2), wherein said 2 nd sealing layer (SL2) comprises at least 90 wt. %, based on the total weight of the 2 nd sealing layer (SL2), of a 3 rd base polymer composition (BC3A) and the remaining part up to 100 wt. %, based on the total weight of the 2 nd sealing layer (SL2), are additives (AD);

said 3 rd base polymer composition (BC3A) comprises at least 70 wt. %, based on the total weight of the 3 rd base polymer composition (BC3A), of a 2 nd linear low density polyethylene (LLDPE2), said 2 nd linear low density polyethylene (LLDPE2) has a density in the range of 0.890 to 0.925 g/cm 3 measured according to ISO 1183-187.

14. The multilayer film according to claim 13 , wherein the 1 st linear low density polyethylene (LLDPE1) and the 2 nd linear low density polyethylene (LLDPE2) have:

(a) a melt flow rate MFR2 (190° C./2.16 kg) measured according to ISO 1133 in the range of 0.5 to 8.0 g/10 min; or

(b) a comonomer content in the range of 1.5 to 5.0 mol.-% determined by quantitative NMR, the comonomers are selected from the group consisting of 1-butene, 1-hexene, 1-octene and mixtures thereof.

15. The multilayer film according to claim 13 , wherein:

(a) the 1 st base polymer composition (BC1):

(a1) consists of the 1 st linear low density polyethylene (LLDPE1), or

(a2) comprises 75 to 95 wt. %, based on the total weight of the 1 st base polymer composition (BC1), of the 1 st linear low density polyethylene (LLDPE1); and

5 to 25 wt. %, based on the total weight of the 1 st base polymer composition (BC1), of a 1 st low density polyethylene (LDPE1) having a density in the range of 0.915 to 0.935 g/cm 3 measured according to ISO 1183-187; or

(b) the outer layer (OL) is the 2 nd sealing layer (SL2) as defined in claim 13 , wherein further the 3 rd base polymer composition (BC3A)

(b1) consists of the 2 nd linear low density polyethylene (LLDPE2), or

(b2) comprises 75 to 95 wt. %, based on the total weight of the 3rd base polymer composition (BC3A), of the 2 nd linear low density polyethylene (LLDPE2); and

5 to 25 wt. %, based on the total weight of the 3 rd base polymer composition (BC3A), of a 1 st low density polyethylene (LDPE2) having a density in the range of 0.915 to 0.935 g/cm 3 measured according to ISO 1183-187.

16. The multilayer film according to claim 13 , wherein:

(a) the 1 st linear low density polyethylene (LLDPE1) and the 2 nd linear low density polyethylene (LLDPE2) are identical

or

(b) the 1 st base polymer composition (BC1) and the 3 rd base polymer composition (BC3A) are identical.

Assignments (2)
CHANGE OF ADDRESS Recorded Feb 23, 2022
From: BOREALIS AG
To: BOREALIS AG
Reel/Frame 059219/0949 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 12, 2021
From: WANG, JINGBO; GAHLEITNER, MARKUS; BERNREITNER, KLAUS; LESKINEN, PAULI; NIEDERSÜSS, PETER
To: BOREALIS AG
Reel/Frame 055889/0364 →